When a standard box shape will not do

Every folded box starts life as a flat sheet cut and scored into shape, and "die-cut" refers to the tool used to do this precisely and repeatedly. While most standard box styles use a stock die, a fully custom die-cut box uses a bespoke tool cut to your own outline, whether that means an unusual shape, a built-in window, a carry handle, or a fitted insert.

Why Choose a Custom Die-Cut Shape

A standard box communicates "off the shelf." A custom die-cut shape, whether it is a branded silhouette, an integrated handle, or a window in an unusual position, signals that packaging was designed specifically around your product, which is often exactly the impression a premium or distinctive brand wants to give.

Where Custom Die-Cutting Is Used

Die-cutting is used across gift packaging, retail displays, insert boxes holding a product firmly in a set shape, and any box needing a window, handle, or non-standard outline. It is also how styles like hanger boxes and window boxes get their distinctive cut-outs.

The Tooling Process

A custom die costs more upfront than using a stock tool, since it is made specifically for your design. This tooling cost is usually a one-off, meaning repeat orders using the same die do not pay for it again, which makes custom die-cutting more cost-effective the more you reorder.

Order Sizes We Support

Custom die-cut boxes are available from around 50 to 100 units for the first run, though we will always confirm tooling lead time and cost separately from the per-unit box price.

Average Prices

As a general guide, die-cut boxes typically cost between £0.50 and £1.80 per unit for the boxes themselves, plus a separate one-off tooling cost for the custom die, depending on shape complexity.

Sustainability

Recyclable folding carton and corrugated board are used for die-cut boxes, and a well-designed die-cut shape can also reduce material waste by nesting more efficiently on the sheet than a generic box outline.

Getting Started

Send us your product's shape and any ideas for handles, windows, or unusual outlines, and our design team will advise on what is realistic to die-cut. We build a proof before production and UK-wide delivery.